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TIFAC-MSME-Internship Scheme
Project Submission Format
1. Title of the proposed project: Adaptation of die casting technique over sand casting to increase
productivity of utensil manufacturing in Mirzapur cluster
2. Name of the Implementing Institution: INDIAN INSTITUTE OF TECHNOLOGY (BHU)-
VARANASI
3. Technical challenge/problem identified (Brief description of problem(s) identified along with details
of industry):
In Utensil manufacturing cluster of Mirzapur, Complexity of the process, and unavailability of
skilled workers and low rate of production in SAND CASTING technique are major problems.
The main four steps involved in SAND CASTING are as follows:
 In the first step pattern is kept inside the frame filled with sand and proper ramming is done.
 In second step pattern is carefully removed and some in gates are made to ease the flow of
molten metal.
 In third step appropriate amount of molten metal is poured into basin of frame so that mould
cavity is completely filled.
 After few minutes (i.e. after solidification) frame is opened to get the casting product.
4. Details of the applicant (students):
 Name : SHUBHAM KUMAR SHILPKAR
 Affiliating Institutions : INDIAN INSTITUTE OF TECHNOLOGY (BHU)-VARANASI
 Contact details : +91-9506595200, shubham.kshilpkar.met13@itbhu.ac.in
 Educational Status : B.Tech PART 3, METALLURGICAL ENGINGINEERING
 Experience if any in the field of proposed work : Family business(Casting of Brass utensils)
5.Details of associated guide/mentor
 Name :Dr. KAMLESH KUMAR SINGH
 Contact details : +91-9956949289, kksingh.met@iitbhu.ac.in
6. Brief write-up giving broad details of the proposed solution (including types of solution- raw material,
process, product, design, packaging, any other etc. original idea/ invention/ IPR/ Novelty and the
scientific/working principles and other technical details involved therein. For details scheme
document may be referred ):
The process of production of brass utensils by sand casting is very complex, it takes too much
time hence reduces the production rate and also the lack of skilled worker is one of the biggest
problems faced by small scale industries. So it is very important to replace the old conventional
process by new process e.g. DIE CASTING.
Advantages of this technique are: High-speed production, Dimensional accuracy and
stability, Strength and weight, Multiple finishing techniques, Simplified Assembly.
So under this project we are going to find/make a suitable material to make DIE and a suitable
design of it as required for casting product.
7. Status of the work already carried out such as:
o Literature survey/patent search:
o Development work done so far, including involvement of agencies, consultation with

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experts/mentor/guide etc.
o Patenting of the innovation, if any
o Preliminary work done towards tie-up for design, fabrication etc with any external agencies, if
any. Provide details.
o Any assessment performed towards finding out techno-economic / market feasibility etc. of the
proposed solutions, if any.
o Industry/ users feedback, if any: Not happy with traditional sand casting techniques, as it is a
complex process as compared to DIE CASTING and also cost of production is high as it
requires more number (at least 4) of skilled workers.
(NOTE: Any supporting documents including literature, photos, test reports, designs, video clips or
research papers etc. may be enclosed)
8. End product / process / output-resulting from the proposed solution :
(Including any drawings, targeted specifications, performance requirements/standards, etc.)
Resulting product of this project will be a process to produce casting (utensils) of very good quality at
a higher production rate.
9. Major applications and users of the solution:
Its major application is in casting of brass utensils and this technique can be used by all small and
micro scale industries of Brass and German Silver Utensil.
10. Activity details during development of solution and its installation for testing & trials:
(Note: Please provide activity time schedule chart)
Activity Assisting Agency Duration
(months)
Design engineering (for
solution development)
/consultancy
Working solution (for
product/process
development )
Product testing and trials/
Process demonstration
NIKET METAL IND. Full time
Any others (please specify)

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11. Detailed break-up of total project cost :
Sr.
No.
Items Cost (Rs) Remarks/Justification
1 *a) Student stipend
(Variable depending on
number of students)
b) Honorarium to Scheme
Coordinator
10,000/month
40,000
2 Development Cost
(subject to actual)
1,00,000
3 Travel Cost
(@ 10% of development
cost)
10,000
4 Institute Overhead
(@ 20% of development
cost)
20,000
5 Miscellaneous and
Contingency
(@ 5% of development cost)
5000
Total 2.35 lacs
(Note: Please refer Point #3.3.1 of the TIFAC –MSME Internship Scheme Document. Individual item
cost should not exceed the maximum limit as provided in the scheme document.)
12. Detailed break-up of development cost (limited up to Rs.1.0 lakhs and subject to actual)
Sl.
No
.
Items
Project Cost
* Basis of
estimation/
justification
Support sought
1 Design / Consultancy charges 10,000
2 **Essential facilities required
3 Material cost 20,000
4 Work sub contracted i.e.
fabrication etc.
30,000
5 Testing and trials 30,000
6 Any other
Total Cost 100000 On the basis of
conversation with
people associated in
concerned industry
(* indicate basis of above cost with justification against each item in a separate Annexure).
(** Please attach a list of equipment/instruments etc. and with their respective costs in a separate
Annexure. Institute requested to provide all existing/available facilities free of cost to the student.)

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13. Justification regarding the following :
a. Proposed solution is most appropriate for the identified problem:
Complexity of the process, unavailability of skilled workers and low rate of production are
major problems faced by industries of Brass and German Silver Utensil, and DIE
CASTING technique checks all these problems.
b. Low cost and easily implementable/adoptable in the industry:
The initial cost of DIE may be quite high but it is a onetime investment as its production
rate is much higher than sand casting and also life of DIE is too long, so overall
production will be cheaper than SAND CASTING.
14. Any other information relevant to the project:
15. Declaration:
I declare that all the statements made in this application are true, complete and correct to the best of
my/our knowledge and belief. I also undertake to submit the project completion report to the Institute.
Place:
Date:
Signature of the applicant (s)
Signature of the Guide/Mentor
(Affiliation and Designation)